Pallet construction



March 5, 1963 J. E. DOANE 3,079,877

PALLET CONSTRUCTION Filed Nov. 2. 1961 4 Sheets-Sheet 1 FIG"! INVENTOR.

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PALLET CONSTRUCTION Filed NOV; 2, 1961 4 Sheets-Sheet 2 INVENTOR. flaw 5 .004:

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PALLET CONSTRUCTION Filed NOV- 2, 1961 4 Sheets-Sheet 4 INVENTOR. Jay/v A", 0044 3,079,877 PALLET CGNSTRUCTHON John E. Doane, 67 Coral Drive, Grinda, Calif. Filed Nov. 2, 1961, Ser. No. 149,638 13 Claims. (Cl. 108-56) This invention relates to pallets useful for providing support platforms upon which a larger number of goods may be stacked for ease of transporting. The goods so palletized can then be conveniently moved from one place to another by a lift truck for shipping and storing.

This application is a continuation-in-part of my application entitled Pallet Construction, U.S. Serial No. 110,- 014, filed on May 15, 1961. As explained in this copending application, pallets are being extensively used today for the storage and transportation of a large number of goods. Usually the goods are placed on pallets at their point of manufacture or assembly and are moved, with the aid of lift trucks, to carriers for shipment to their place of destination. Often the goods remain palletized, that is, remain stacked on pallets during shipment, thereby facilitating handling which produces a considerable saving of time and cost.

As has also been explained in the co-pending application, pallets should be light in weight so that their weight does not add materially to the weight of the goods to be shipped, thereby increasing the transportation cost therefor. Furthermore, pallets that can be easily assembled at their point of use are desirable so that prior to use their storage space may be kept to a minimum. Furthermore, in certain instances, pallets are desired for one-timeuse after which they may be discarded. Such expendable pallets therefore should be inexpensive to produce so that theircost, which has to be absorbed in the price of the goods, remains at an absolute minimum. In certain other instances it is desirable to utilize pallets which are returned to the point of origin for re-use. In case of re.- usable pallets it is desirable that the pallets be capable of being knocked down or disassembled for shipment or storage and later re-use. The co-pending application describes a pallet having a lower and upper folda-ble platform separated by a plurality of honeycombed support members which are expandable and contractable in accordion-like manner. Both plat: forms are scored to provide parallel fold-lines passing through the center of the platforms-and are held together by side walls to which the support members are affixed. Even though this pallet is light-weight, collapsible, in expensive and extremely sturdy, it has been found that certain, modifications of its construction facilitates its fabrication and particularly the aifixing of the support members to the side panels and thereby further reduces the price of manufacture without loss of .sturdiness and versatility.

Whereas one of the features of the pallet described in the co-pending application was a construction in which the upper or load-receiving platform, the side panels and the lower platform were permanently connected, that is, connected in' its collapsed and its assembled state, the present invention contemplates various arrangements in which the pallet, in its collapsed state, has separate parts comprising various combinations of platforms and side panels. 7 7

It is therefore an object of this invention to provide a light-weight, inexpensive pallet suitable to be stored in a collapsed state and which is easily assembled.

It is a further object of this invention to provide an improved pallet in which the honeycomb support members are aflixed to portions of the pallet frame which 'are' separate in the collapsed state.

- It is another object of this invention to provide a pal- United States atent let which is more easily manufactured than pallets known heretofore and which can be readily assembled at the point of use with staples, glue or the like.

, Other objects and a fuller understanding of the invention may be had by reference to the following description and taken in conjunction with the accompanying drawings in which:

FIGS. 1 to 4 are isometric views of a preferred embodiment of the pallet in this invention. More particularly, FIG. 1 shows the pallet in its collapsed state; FIG. 4 shows the pallet in its fully assembled state; and FIGS. 2. and 3 show intermediate stages of the pallet when being assembled.

FIGS. 5 to 7 are isometric views of another embodiment of the pallet of this invention. More particularly, FIG. 5 shows the pallet in its collapsed state; FIG. 7 shows the pallet in its assembled state; and FIG. 6 shows the pallet in an intermediate state when being assembled.

FIGS. 8 to 10 are isometric views of a further embodiment of the pallet of this invention. More particularly, FIG. 8 shows the pallet in its collapsed state; FIG. 10 shows the pallet in its assembled state; and FIG. 9 shows an intermediate state of the pallet when being assembled.

Referring now to the drawings, in which like reference characters designate like parts, the pallet shown in FIGS. 1 to 4 and generally designated 10 includes an upper load bearing platform 12, a lower platform 14-, two side panels 16 and 18 and two overlap panels 20 and 26. Platform 12, side panel 16 and overlap panel 26 may comprise a single sheet of corrugated cardboard scored along fold lines 22 and 24 which respectively define the edges of the three panels. Similarly, platform 14, side panel 18 and overlap panel 26 may be formed of a single sheet of corrugated cardboard scored along fold lines 23 and 30.

Instead of employing corrugated cardboard which is light, sturdy and inexpensive, this invention also contemplates the use of more permanent materials, such as Masonite, wood, resin-bonded pulp, etc. For those materials which do not readily lend themselves to bending about scored fold-lines, the three panels-may be foldabl y connected to one another along their edges by tape or some other well known fastening materials or adhesive which allows bending.

Four honeycombed support members, 30, 32, 34 an 36, expandable and contractable in accordion-like manner, have opposite ends securely fastened respectively to side panels 16 and 18 by conventional fastening means such as glue, staples or tacks. Side panels 16 and 18. are also provided with cut-outs 38, 40 and 42, 44 respectively, which define a pair of passageways 48, 50 when pallet 10 is in its assembled state as shown in FIG. 4. Passageway 48 is bordered on its top and bottom by platforms 12 and 14 respectively and along its side by honeycombed support members 36 and 32. Similarly, passageway 50 is bordered on top and bottom by platforms 12 and 14 respectively and along the sides by support members 34 and 36. Passageways 48 and 50, as will become clearer hereinafter, are provided to receive the forks of a lflorklift truck to move pallet 10 from one place to anot er.

As is fully explained in the co-pending application, honeycomb support members 30, 32, 34 and 36 may be made of paper or other suitable material, and in case of re-usable pallets may be impregnated with a suitable resin or plastic for greater resistance to moisture and other environmental conditions. which may tend to weaken it. The support propertes of extended honeycomb material are very great, a A" cell honeycomb paper web being rated for a compression strength of about 60 lbs. per square inch. Consequently, a pallet having a width of 48" and a length of 42" and being provided with four honeycomb support members, each 6" wide, can sup- 3 V port a safe, evenly-distributed load of about 60,000 lbs. Much greater safe load ratings for pallets constructed in accordance with th's invention are obtainable by utilizing honeycomb material of smaller cell structure.

Pallet shown in FIG. 1 is in its collapsed state in which upper platform 12, side panel 16 and overlap panel 20 are lying in the same plane, i.e., none of the panels is bent about its fold line. Honeycomb support members 30, 32, 34 and 36 are in their collapsed position and connect side panels 16 and 18 respectively. Lower platform 14 is substantially parallel to upper platform 12 and is folded about fold line 28 to be back-to-back with side panel 18.

In certain instances, especially in case of re-usable pallets, it might be found desirable to provide a pair of liners 52'and 54 for passages 48 and 50. Thes liners may comprisea fiat piece of corrugated cardboard or other similar material scored to have a pair of fold lines to form a U-shaped channel member as'shown in FIG. 2.

In their flat unfolded position, liners 42 and 44 may be stored between platforms 12 and 14 as shown in FIG. 1.

FIG. 2 shows the first step in assembling the pallet of this invention. Lower platform 14 is folded about fold-line 28 through an angle of 180 degrees to extend downwardly. The next step is best outlined in FIG. 3, in which side panels 16 and 18 are separated as shown by arrow 60, thereby extending honeycomb support members 30, 32, 34 and 36. At the same time, load-bearing upper platform 12 is bent along fold-line 22 in the direction of arrow 62 to lie'fiat across the upper sides of the honeycomb support members. Similarly, lower platform 14 is again bent about fold-line 28 in the direction shown by arrow 64, to form the bottom of pallet 10; Overlap panel 20 is then folded about fold-line 24 as shown by arrow 66 and secured to the end portion of paltform 14 by means of staples, glue or other kind of adhesive. Similarly panel 26 is folded about fold-line 30 in the direction of arrow 68 and attached to the upper end portion of load-bearing platform 12 as best shown in FIG. 4. Affixing of panel 26 to platform 12 may be accomplished by staples 70 which may be removed for collapsing pallet 10 back into the position shown in FIG. 1.

Referring now to the embodiment of the pallet. shown in; FIGS. 5, 6, and 7, and generally designated by the reference character 80, the pallet there shown includes a load platform may be collapsed by folding both the upper and a hearing upper platform 82, a pair of side panels 88, and

89 fastened to opposite sides of platform 82, two overlap panels 90. and 91 fastened respectively to side panels. 88 and 89 and a lower platform 97. Upper platform 82, side panels 88 and 89 and over-lap panels 90, and 91- may comprise a single sheet of corrugated cardboard scored along fold-lines 83, 84, 86 and 87'. Also, upper, platform isscored'along a fold line 85 so. it may be. folded into two substantially equal parts.

Instead of scoring a single sheet of corrugated card,- board, the various panels separatedby, fold-lines may comprise separate, pieces fastened together by tape as explaned in connection with the construction. of the pallet shown in FIG. 4. Likewise, other material may replace, corrugated cardboard if a pallet of more permanenc is: desired; Firmly aflixed to side panels 88 and 89- are the opposite ends of four honeycomb support, members 92, 93, 94 and 95 which may be similar to the construction of support members, 30, 32, 34 and 36 as1described above and which serve as spacers between platforms 82. and 97.

FIG. 5 shows the embodiment of this; palletconstruc tion in its collapsedstate, lower'platform 97 being omitted since it comprises-a planar single member, and upper platform being folded about fold-line 85'. Upon assembly, sidepanels 88 and 89 are pulled' apart which expands support members to 95 and straightens out upper-plat form 82 in the direction of arrow 96, as best shown in FIG. 6. Whenever platform 82 assumes its planar c,on figuration, it lies on top of honeycomb support members.

r 4 r 92 to 95. Lower platform 97, which is dimensioned to be similar in size to upper platform 82, is placed to lie across the bottom of honeycomb support members 92 to 95. Over-lap panels and 91 are turned about fold lines 83 and 87 respectively and fastened to lower platform 89 by conventional means. '88 and 89 may' be provided with rectangular openings 98 and 99 to form channels or passageways for receiving the forks of a forklift truck.

It is also within the contemplation of this invention to provide a lower platform 97 scored along a centrally positioned fold-line so that after being assembled, the

the lower platform about centrally positioned fold-lines. The advantage of this pallet embodiment over the one described in the above-referred to co-pending application is that during fabrication the ends of support members 92 to may be firmly fastened to easily accessible flats located at opposite extremities of a single small flat sheet. It has been found that attachment of the support member proximate to the ends of a flat sheet which does not include both the upper and the lower platforms has certain manufacturing advantages over fastening the ends of the support members to a mid-portion of the large sheet '(includ ng both platforms) as shown in the co-pending' application.

A further embodiment of a pallet in accordance with this invention is shown in FIGS. 8 to 10 and designated by reference numeral 100. Pallet 100 comprises an upper and a lower platform 120 and 121, four support members 103 to 106, a pair of side panels 101 and 102, and two pairs of over-lap panels 116, 117, 118 and 119. Side panels 101 and over-lap panels 116 and 117 may comprise a single sheet of corrugated cardboard which is scored along fold-lines 109 and 110. Similarly side panel 7 102 and overlap panels 118 and 119 may comprise a sin gle sheet of corrugated cardboard scored along fold-lines 111 and 112. Honeycomb support members 103 to 106 have opposite ends respectively fastened to side panels 101 and 102. Also side panels 101 and 102 may be provided with openings 107 to 110 respectively, through which the forks of a forklift truck' may pass.

Pallet 100 shown in FIG. 8 in its collapsed position (without the platforms) is assembled bypulling side panels 101 and 102 apart so that honeycomb members 103 to 106 are extended. Platforms and 121 are respectively laid across the top. and the bottom of support members 103 to 106. Overlap panels 117 and 118 are folded across fold-lines 109 and 110 and stapled to platform 120 and over-lap panels 116' and 119. are folded.

across fold lines 110 and. 112 stapled'to lower platform From a manufacturing standpoint, pallet 100 has the advantage of afiixiug the support members to very short side panels. Furthermore the combination of side panels: and s pport members isvery compact and easily shipped. Platforms of flat corrugated paper can be obtained from. other sourcesin case their bulk of weight should. make it uneconomioal' to. ship to far distant. P ints Also, with. pallet 100, defective, or damaged platforms are.v easily replaced thereby extending the. life of the. support mema hers and, side, panel combination which form the, more cos lyv P rtion of the pallet.

There has been described a new and, novel pallet which is easy; and; inexpensive to, manufacture and which, is rugged in construction, light weight and inexpensive. The pallets may be sold and shipped, in their collapsed state' and are easily assembled for providing a supportupon which goods may be stacked for shipment.

ha s. aime s:

1 A pallet construction comprising; first and-v second substantially rectangular fiat body members. each, having;- a pair of parallel, lengthwise extendingv scored. fold lines about which portions. of said body member are folded;

As before, side panels and a plurality of honeycomb support members having opposite ends respectively afiixed to the portion of said first and second body member lying between said pair of fold lines, the portions of said first member lying outside said pair of fold lines forming respectively a load receiving upper platform and a first narrow overlap panel and the portions of said second body member lying outside said pair of fold lines forming respectively a lower platform and a second narrow overlap panel.

2. A pallet construction comprising: first and second substantially rectangular flat body members each having a pair of parallel, lengthwise extending scored fold lines, the portions of said body member between said fold lines being parallel and opposite and defining a pair of side panels; and a plurality of honeycomb support members having opposite ends respectively affixed to said side panels, the portions of said first and second body members lying outside said pair of fold lines being folded through an angle of ninety degrees to lie across opposite sides of said support members to respectively form upper and lower platforms and narrow overlap panels attached to said platforms.

3. A pallet construction in accordance with claim 2 in which said honeycomb support members have a height equal to the distance between said fold lines and in which each of said side panels includes a pair of rectangular openings in registry with one another to define a pair of passageways for receiving the fork of a forklift truck.

4. A pallet construction in accordance with claim 3 in which honeycomb support members are disposed on both sides of said passageways.

5. A pallet having a collapsed and an assembled state comprising: a first body member including an upper load receptive platform, a first side panel and a first overlap panel, said upper platform and said first overlap panel being foldably connected to opposite lengthwise edges of said first side panel; a second body member including a lower platform, a second side panel and a second overlap panel, said lower panel and said second overlap panel being foldably connected to opposite lengthwise edges of said second side panel; and a plurality of expandable and contractable honeycomb support members having a height substantially equal to the widths of said side panels, opposite ends of said honeycomb members being permanently affixed to said first and second side panels, said platforms, panels and honeycomb members being arranged so that in the collapsed state of said pallet said honeycomb members are in their contracted position, said upper platform and said first side panel forming a substantially planar surface and said lower platform and said second side panel being folded through an angle of substantially 180 degrees, and in the assembled state of said pallet said upper platform, said lower platform and said first and second side panels form a substantially rectangular box, said honeycomb members are in their expanded position across the width of said box and said first and second overlap panels are respectively contiguous with and fastened to the lower and upper platforms.

6. A pallet having a collapsed and an assembled state and comprising: first and second substantially identical body members including respectively a first and second long platform, a first and second side panel and a first and second short overlap panel, said first and second platform and said first and second overlap panels being re spectively foldably connected to opposite lengthwise edges of said first and second side panels; and a plurality of expandable and contractable honeycomb support members having opposite ends permanently afiixed to said first and second side panels, said platforms, panels and support members being arranged so that in the collapsed state of said pallet said support members are in their contracted position between parallel and oppositely positioned side panels, said first platform forming a planar upward extension of said first side panel and said second platform being folded through an angle of substantially degrees to extend upward and parallel to said first platform, and in the assembled state of said pallet said side panels being separated to expand said support members, said first and second platforms being folded in opposite directions to assume an angle of substantially ninety degrees with said side panels to form a substantially rectangular box, and said first and second overlap panels being respectively secured to said second and first platforms.

7. A pallet as defined in claim 6 in which said side panels include a pair of openings defining a passageway though said pallet is in its assembled state for receiving the forks of a forklift truck.

8. A pallet construction as defined in claim 7 which includes a liner means having a center portion and two side portions foldably connected lengthwise to the edges of said center portion, said center and side portions being dimensioned for accommodation in said passageways.

9. A pallet comprising: a load receiving upper platform foldable about a substantially centrally positioned, lengthwise extending, scored fold line; a pair of side panels foldably connected to opposite lengthwise edge portions of said upper platform; a pair of overlap panels foldably connected to the remaining lengthwise edge portion of said pair of side panels; a plurality of expandable and contractable support members having opposite ends affixed respectively to the inner surfaces of opposite side panels, said upper platform being folded about its fold line when said support members are in their contracted position and being planar and lying on top of said support members when said support members are in their expanded position; and a lower platform dimensioned for placement across the bottom of said support members and between opposite overlap panels, said overlap panels being folded over said low platform and afiixed thereto when said pallet is assembled.

10. A pallet comprising: a substantially rectangular flat body member including a first pair of symmetrically spaced, lengthwise extending scored fold lines defining a load receiving upper platform portion therebetween, said 'body member including a second pair of symmetrically spaced, lengthwise extending scored fold lines outside said first pair of fold lines, the portions of said body member between said first and second pair of fold lines defining a pair of side panel portions and outside said second pair of fold lines defining a pair of overlap panel portions, said platform portion having a centrally spaced lengthwise extending scored fold line; a plurality of expandable and contractable support members having opposite ends afiixed respectively to opposite side panel portions, said upper platform portion being folded about its fold line when said support members are in their contracted position and being planar and lying on top of said support members when said support members are in their expanded position; and a lower platform dimensioned for placement across the bottom of said support members and between opposite overlap panel portions, said overlap panel portions being folded over said lower platform portion and afiixed thereto when said support members are in their expanded position.

11. A pallet construction as defined in claim 10 in which said side panel portions include a pair of openings defining a passageway through said pallet when said support members are in their expanded position for receiving the forks of a forklift truck.

12. A pallet comprising: a pair of side panels; overlap panels foldably connected to opposite lengthwise edge portions of each of said pair of side panels; a plurality of expandable and contractable honeycomb support members having opposite ends atlixed respectively to said pair of side panels, the height of said support members being substantially equal to the width of said side panels; and a pair of substantially planar rigid platforms placed on opposite sides of said support members when said support members are in their expanded state and between said overlap panels, said overlap panels being fastened to the surfaces of said platforms.

13. A pallet construction as defined in claim 12 in which said side panels include a pair of openings defining References Cited in the file of this patent UNITED STATES PATENTS Simkins Mar. 20, 1962 

1. A PALLET CONSTRUCTION COMPRISING: FIRST AND SECOND SUBSTANTIALLY RECTANGULAR FLAT BODY MEMBERS EACH HAVING A PAIR OF PARALLEL, LENGTHWISE EXTENDING SCORED FOLD LINES ABOUT WHICH PORTIONS OF SAID BODY MEMBER ARE FOLDED; AND A PLURALITY OF HONEYCOMB SUPPORT MEMBERS HAVING OPPOSITE ENDS RESPECTIVELY AFFIXED TO THE PORTION OF SAID FIRST AND SECOND BODY MEMBER LYING BETWEEN SAID PAIR OF FOLD LINES, THE PORTIONS OF SAID FIRST MEMBER LYING OUTSIDE SAID PAIR OF FOLD LINES FORMING RESPECTIVELY A LOAD RECEIVING UPPER PLATFORM AND A FIRST NARROW OVERLAP PANEL AND THE PORTIONS OF SAID SECOND BODY MEMBER LYING OUTSIDE SAID PAIR OF FOLD LINES FORMING RESPECTIVELY A LOWER PLATFORM AND A SECOND NARROW OVERLAP PANEL. 